Compound cycle engine

ABSTRACT

A compound cycle engine having at least one rotary unit defining an internal combustion engine, a velocity turbine in proximity of each unit, and a turbocharger is discussed. The exhaust port of each rotary unit is in fluid communication with the flowpath of the velocity turbine upstream of its rotor. The rotors of the velocity turbine and of each rotary unit drive a common load. The outlet of the compressor of the turbocharger is in fluid communication with the inlet port of each rotary unit, and the inlet of the pressure turbine of the turbocharger is in fluid communication with the flowpath of the velocity turbine downstream of its rotor. A method of compounding at least one rotary engine is also discussed.

TECHNICAL FIELD

The application relates generally to compound cycle engines and, moreparticularly, to such compound cycle engines including one or morerotary combustion engine(s).

BACKGROUND OF THE ART

Some compound cycle engines include a rotary engine turbocharged andcompounded by a turbine located downstream of the turbocharger turbine.However, known compounded rotary engine arrangements typically havelimited available power for turbo compounding and/or limitedperformances, for example on start-up before the turbocharger isrunning.

SUMMARY

In one aspect, there is provided a compound cycle engine comprising: atleast one rotary unit with each unit defining an internal combustionengine including a rotor sealingly and rotationally received within arespective housing, each housing defining an inlet port and an exhaustport; a velocity turbine in proximity of each unit and including a rotorsupporting a circumferential array of blades extending across aflowpath, the exhaust port of each housing being in fluid communicationwith the flowpath upstream of the rotor of the velocity turbine, therotor of the velocity turbine and the rotor of each unit being indriving engagement with a common load; and a turbocharger including acompressor and a pressure turbine in driving engagement through a sameshaft, an outlet of the compressor being in fluid communication with theinlet port of each housing, and an inlet of the pressure turbine beingin fluid communication with the flowpath downstream of the rotor of thevelocity turbine.

In another aspect, there is provided a compound cycle engine comprising:at least one rotary engine having a rotor sealingly and rotationallyreceived within a respective housing having an inlet port and an exhaustport, the rotor of each rotary engine being drivingly engaged to acommon load; a velocity turbine in proximity of each rotary engine andhaving a rotor drivingly engaged to the common load; a respectiveexhaust pipe providing fluid communication between each exhaust port andthe velocity turbine upstream of the rotor thereof; a turbochargerincluding a compressor and a pressure turbine drivingly engaged to asame shaft; an inlet duct providing fluid communication between anoutlet of the compressor and the inlet port of each rotary engine; and aturbine pipe providing fluid communication between an outlet of thevelocity turbine and an inlet of the pressure turbine.

In a further aspect, there is provided a method of compounding at leastone rotary engine, the method comprising: drivingly engaging a pressureturbine and a compressor in a turbocharger; defining a fluidcommunication between an outlet of the compressor and an inlet port ofeach rotary engine; defining a fluid communication between an exhaustport of each rotary engine and an inlet of a velocity turbine, includingdirecting the fluid communication onto blades of a rotor of the velocityturbine; defining a fluid communication between an outlet of thevelocity turbine and an inlet of the pressure turbine of theturbocharger; and drivingly engaging each rotary engine and the velocityturbine to a common load.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying figures in which:

FIG. 1 is a block diagram of a compound cycle engine according to aparticular embodiment;

FIG. 2 is a cross-sectional view of a Wankel engine which can be used ina compound cycle engine such as shown in FIG. 1, according to aparticular embodiment;

FIG. 3 is a schematic representation of the compound cycle engine ofFIG. 1 according to a particular embodiment;

FIG. 4 is a schematic tridimensional view of a compound cycle enginesuch as shown in FIG. 3 according to a particular embodiment; and

FIG. 5 is a block diagram of a compound cycle engine according toanother embodiment.

DETAILED DESCRIPTION

Referring now to FIG. 1, a compound cycle engine 10 is schematicallyshown. The compound cycle engine 10 includes one or more rotary units12, each unit 12 being defined by a rotary internal combustion enginehaving a rotor sealingly engaged in a respective housing. The rotaryunit(s) 12 drive a common load. In the embodiment shown, the common loadincludes an output shaft 16 which may be for example connected to apropeller through a reduction gearbox (not shown) and to which the rotorof each unit 12 is engaged.

The compound cycle engine 10 also includes a turbocharger 18, formed bya compressor 20 and a pressure turbine 22 which are drivinglyinterconnected by a shaft 24. The compressor 20 and the turbine 22 mayeach be a single-stage device or a multiple-stage device with a singleshaft or split on multiple independent shafts in parallel or in series,and may be a centrifugal or axial device. In the embodiment shown, theshaft 24 of the turbocharger 18 rotates independently of the commonload. The compressor 20 of the turbocharger 18 compresses the air beforeit enters the unit(s) 12.

The rotary unit(s) 12 form the core of the compound cycle engine 10 andeach provide an exhaust flow in the form of exhaust pulses. The exhaustflow from the unit(s) 12 is supplied to a power turbine 26 in fluidcommunication therewith, also driving the common load. The power turbine26 is a velocity type turbine, also known as an impulse turbine, andcould be an axial, radial or mixed flow turbine.

In a velocity turbine, the fluid is deflected without a significantpressure drop in the blade passages. Velocity turbines thus differ frompressure turbines in that in the pressure drop occurring over the rotorin a pressure turbine is not present in a velocity turbine. Velocityturbines typically have blades with different cross-sections thatpressure turbines; for example, blades of pressure turbines usually havea change in flow area as the working fluid circulates therethrough,while blades of velocity turbines usually have a constant flow area;blades of pressure turbines are usually not symmetrical about the planeof the rotating disc, while blades of velocity turbines usually are.Each blade of the velocity turbine 26 thus forms a bucket pushed by theexhaust flow. The rotor of the power turbine 26 is rotated by the forcescreated on the blades by the impingement against them of the exhaustpulses. As such, the kinetic energy provided by each exhaust pulse isused to drive the rotor of the power turbine 26 while imposing minimumback pressure on the rotary unit(s) 12.

The power turbine 26 is connected to the output shaft 16 through anappropriate type of transmission 28, for example a planetary, star,offset or angular gear system. The outlet of the power turbine 26 is influid communication with an inlet of the turbocharger turbine 22. Energyis extracted from the exhaust gas exiting the power turbine 26 by theturbocharger turbine 22 to drive the compressor 20 via the connectingshaft 24.

Although not shown, the air may optionally circulate through anintercooler between the compressor 20 and the unit(s) 12, and thecompound cycle engine 10 also includes a cooling system, including forexample a circulation system for a coolant (e.g. water-ethylene, oil,air) to cool the housing of each unit 12, an oil coolant for theinternal mechanical parts of the unit(s) 12, one or more coolant heatexchangers, etc.

The fuel injector(s) of each unit 12, which in a particular embodimentare common rail fuel injectors, communicate with a source 30 of Heavyfuel (e.g. diesel, kerosene (jet fuel), equivalent biofuel), and deliverthe heavy fuel into the unit(s) 12 such that the combustion chamber isstratified with a rich fuel-air mixture near the ignition source and aleaner mixture elsewhere.

In a particular embodiment each unit 12 is a Wankel engine. Referring toFIG. 2, an exemplary embodiment of a Wankel engine is shown; it isunderstood that the configuration of the unit(s) 12 used in the compoundcycle engine 10, e.g. placement of ports, number and placement of seals,etc., may vary from that of the embodiment shown; each unit 12 may bedefined by a rotary engine other than a Wankel engine.

As shown in FIG. 2, in a particular embodiment, each unit 12 comprises ahousing 32 defining a rotor cavity with a profile defining two lobes,which is preferably an epitrochoid. A rotor 34 is received within therotor cavity. The rotor defines three circumferentially-spaced apexportions 36, and a generally triangular profile with outwardly archedsides. The apex portions 36 are in sealing engagement with the innersurface of a peripheral wall 38 of the housing 32 to form three workingchambers 40 between the rotor 34 and the housing 32.

The rotor 34 is engaged to an eccentric portion 42 of the output shaft16 to perform orbital revolutions within the stator cavity. The outputshaft 16 performs three rotations for each orbital revolution of therotor 34. The geometrical axis 44 of the rotor 34 is offset from andparallel to the axis 46 of the housing 32. During each orbitalrevolution, each chamber 40 varies in volume and moves around the statorcavity to undergo the four phases of intake, compression, expansion andexhaust.

An intake port 48 is provided through the peripheral wall 38 foradmitting compressed air into one of the working chambers 40. An exhaustport 50 is also provided through the peripheral wall 38 for discharge ofthe exhaust gases from the working chambers 40. Passages 52 for a sparkplug or other ignition mechanism, as well as for one or more fuelinjectors (not shown) are also provided through the peripheral wall 38.Alternately, the intake port 48, the exhaust port 50 and/or the passages52 may be provided through an end or side wall 54 of the housing.

For efficient operation the working chambers 40 are sealed, for exampleby spring-loaded apex seals 56 extending from the rotor 34 to engage theperipheral wall 38, and spring-loaded face or gas seals 58 and end orcorner seals 60 extending from the rotor 34 to engage the end walls 54.The rotor 34 also includes at least one spring-loaded oil seal ring 62biased against the end wall 54 around the bearing for the rotor 34 onthe shaft eccentric portion 42.

Each Wankel engine provides an exhaust flow in the form of a relativelylong exhaust pulse; for example, in a particular embodiment, each Wankelengine has one explosion per 360° of rotation of the output shaft, withthe exhaust port remaining open for about 270° of that rotation, thusproviding for a pulse duty cycle of about 75%. By contrast, a piston ofa reciprocating 4-stroke piston engine typically has one explosion per720° of rotation of the output shaft with the exhaust port remainingopen for about 180° of that rotation, thus providing a pulse duty cycleof 25%. In a particular embodiment, the relatively long exhaust pulse ofthe Wankel engine may facilitate driving of the velocity power turbine26.

The pressure ratios across a compound cycle engine with one or morerotary engines or units can be defined by:

P_(C)=P_(R)P_(PT)P_(TT)

where P_(C) is the pressure ratio for the turbocharger compressor, P_(R)is the inlet to outlet pressure ratio of the rotary engines, P_(PT) isthe pressure ratio for the power/compound turbine, and P_(TT) is thepressure ratio for the turbocharger turbine.

The inventors have found that in prior art compound engines includingone or more rotary engines where the power turbine is a pressure turbinelocated downstream of the turbocharger turbine, and where each rotaryengine has equal volumetric expansion and compression ratios, therelatively high volumetric compression ratio of the rotary engine(s)typically results in a relatively low possible pressure ratio for thecompressor of the turbocharger (P_(C)), as limited by the peak pressurecapability of the rotary engine(s). As such, the pressure ratio acrossthe turbines (P_(PT)P_(TT)) is limited, which limits the power availablefor the power turbine.

In some compound engines, such as shown in U.S. Pat. No. 7,775,044issued Aug. 17, 2010 and incorporated by reference herein, thevolumetric compression ratio of each rotary engine is smaller than itsexpansion ratio. The lower volumetric compression ratio typicallyresults in a larger possible pressure ratio for the compressor of theturbocharger (P_(C)), which in turn increases the pressure ratio acrossthe turbines (P_(PT)P_(TT)). However, the lower volumetric compressionratio usually leads to an inlet to outlet pressure ratio of the rotaryengine(s) which is reduced P_(R), which may increase back pressure andthermal loads on the rotary engine(s) because of the increaseddifficulty in purging the exhaust gases. Such a configuration alsogenerally provides for a low compression on the rotary engine onstart-up before the turbocharger is running, which may limitperformances of the compound cycle engine.

By contrast, in the compound cycle engine 10, the pressure ratio P_(PT)across the power turbine 26 is about 1 since it is a velocity turbine.As such, a same pressure ratio for the compressor P_(C) (to comply withthe peak pressure capability) and a same inlet to outlet pressure ratioof the rotary unit(s) P_(R) (to minimize backpressure and thermalloading on each rotary unit) allow for the pressure ratio P_(TT)available for the turbine 22 of the turbocharger 18 to be greater thanwith a compound cycle engine in which the power turbine is a pressureturbine, i.e. with a pressure ratio P_(PT) greater than 1. Thus, the useof a velocity turbine as the power turbine 26 may allow for an increaseof the power available to the turbo compounding.

In addition, the volumetric compression ratio of the rotary unit(s) 12does not need to be reduced to achieve this increase in power availablefor the turbine 22 of the turbocharger 18. As such, in a particularembodiment, the volumetric efficiency of each rotary unit may bemaximized and its thermal loads minimized, and the performances of thecompound cycle engine 10 at start-up are not compromised by the increaseof available power.

Also, the use of a velocity turbine as the power turbine 26 eliminatesthe need for the large volume exhaust collector typically requiredbetween the rotary engine(s) and a pressure power turbine. This allowsfor the power turbine 26 to be located upstream of the compound turbine22 instead of downstream thereof.

In a particular embodiment which may be particularly but not exclusivelysuitable for low altitude, each rotary unit 12 is a Wankel engine with avolumetric compression ratio of from 6:1 to 8:1. The power recovery ofthe velocity turbine 26 may be maximized by having the exhaust gastemperatures at the material limit, and as such is suitable for suchrelatively low volumetric compression ratios, which may help increasethe power density of the Wankel engine and may also improve combustionat high speed and of heavy fuel.

Referring to FIGS. 3-4, a compound cycle engine 10 according to aparticular embodiment is schematically shown. In this embodiment, tworotary units 12 in the form of Wankel engines are included, with the twoeccentric portions 42 of the output shaft 16 being angularly offset at180° from one another for balancing of the compound cycle engine 10. Inother embodiments, more or less rotary engines may be provided.

The rotor blades 64 of the velocity power turbine 26 extend across anannular flowpath 66. In the embodiment shown, the rotor of the powerturbine 26 is an axial rotor and the flowpath 66 extends axially. Arespective exhaust pipe 68 extends from the exhaust port 50 (see alsoFIG. 2) of each unit 12 to the flowpath 66, upstream of the rotor blades64. The exhaust pipes 68 extend independently from one another, andtheir length are minimized to maximize use of the exhaust pulse kineticenergy to drive the power turbine 26. The flowpath 66 and/or the outletof each exhaust pipe 68 are shaped to direct the exhaust pulses onto theblades 64 to allow the exhaust pulses to drive rotation of the rotor ofthe power turbine 26. As can be seen more clearly from FIG. 4, eachexhaust pipe 68 communicates with the flowpath 66 at a differentlocation around the circumference of the power turbine 26.

A pipe 70 extends from an outlet of the compressor 20, and splits intotwo inlet pipes 72, each connected to the intake port 48 (see also FIG.2) of the respective rotary unit 12. In this embodiment, the compressor20 includes a single radial impeller 74. Alternately, the compressor 20may include one or more rotors, with radial, axial or mixed flow blades.

In the embodiment shown, the transmission 28 of the power turbine 26includes a sun gear 76 attached on the shaft of the rotor of the powerturbine 26, and an array of planet gears 78 meshed with the sun gear 76.The planet gears 78 are mounted on a rotating carrier which is drivinglyengaged to the output shaft 16. The planet gears 78 are meshed with astationary ring gear 79. In another embodiment, the planet gears 78 aremounted on a stationary carrier, and are meshed with a ring geardrivingly engaged to the output shaft 16. The speed reduction ratio ofthe transmission 28 may be selected to optimize operation of thevelocity power turbine 26 and of the rotary units 12.

A turbine pipe 80 extends from the flowpath 66 downstream of the rotorblades 64 to the inlet of the turbocharger turbine 22. In thisembodiment, the turbocharger turbine 22 includes a single radialimpeller 82. Alternately, the turbocharger turbine 22 may include one ormore rotors, with radial, axial or mixed flow blades.

The turbocharger shaft 24 extends along a different axis than that ofthe output shaft 16. In the particular embodiment shown in FIG. 4, theturbocharger shaft 24 extends transverse to the output shaft 16. Theturbocharger shaft 24 may additionally be connected to a different loadthan that of the output shaft 16, through a gearbox if necessary.

Referring to FIG. 5, a compound cycle engine 110 according to anotherembodiment is schematically shown, where elements similar to those ofthe previously described compound cycle engine 10 are identified by thesame reference numerals and will not be further described therein. Inthis embodiment, the turbocharger 118 is defined coaxially with theoutput shaft 16. The compressor 120 is connected to the output shaft 16through an appropriate type of transmission 128, for example a planetaryor star gear system. The pressure turbine 122 of the turbocharger 118 isconnected to the velocity power turbine 26 to rotate together therewith,or else connected to the output shaft 16 through an appropriate type oftransmission (not shown).

In another embodiment which is not shown, the turbocharger and rotaryunit(s) are coaxial, but the output shaft and turbocharger shaft rotateindependently from one another, for example with the output shaft beinghollow and surrounding the turbocharger shaft which extendstherethrough.

Although not shown, in all embodiments, variable geometry elements suchas inlet guide vanes, blow-off valves, waste gates, variable turbinenozzles, etc. may be used to obtain desired system operability.

Although not shown, the velocity power turbine 26 may be mounted in anoffset manner rather than co-axially with the rotary units 12. The powerturbine 26 may be drivingly engaged to the output shaft through anangular, for example perpendicular, transmission system, for exampleincluding a gearbox and a tower shaft.

The above description is meant to be exemplary only, and one skilled inthe art will recognize that changes may be made to the embodimentsdescribed without departing from the scope of the invention disclosed.Modifications which fall within the scope of the present invention willbe apparent to those skilled in the art, in light of a review of thisdisclosure, and such modifications are intended to fall within theappended claims.

1. A compound cycle engine comprising: at least one rotary unit witheach unit defining an internal combustion engine including a rotorsealingly and rotationally received within a respective housing, eachhousing defining an inlet port and an exhaust port; a velocity turbinein proximity of each unit and including a rotor supporting acircumferential array of blades extending across a flowpath, the exhaustport of each housing being in fluid communication with the flowpathupstream of the rotor of the velocity turbine, the rotor of the velocityturbine and the rotor of each unit being in driving engagement with acommon load; and a turbocharger including a compressor and a pressureturbine in driving engagement through a same shaft, an outlet of thecompressor being in fluid communication with the inlet port of eachhousing, and an inlet of the pressure turbine being in fluidcommunication with the flowpath downstream of the rotor of the velocityturbine.
 2. The compound cycle engine as defined in claim 1, whereineach unit is a Wankel engine.
 3. The compound cycle engine as defined inclaim 2, wherein each Wankel engine has a volumetric compression ratiowithin a range defined from 6:1 to 8:1.
 4. The compound cycle engine asdefined in claim 1, wherein the compound cycle engine includes at leasttwo units, the exhaust port of each housing being in fluid communicationwith a respective velocity turbine inlet, the velocity turbine inletsbeing circumferentially spaced apart.
 5. The compound cycle engine asdefined in claim 1, wherein the flowpath of the velocity turbine is anaxial flowpath.
 6. The compound cycle engine as defined in claim 1,wherein the same shaft of the turbocharger rotates independently of thecommon load.
 7. The compound cycle engine as defined in claim 1, whereinthe same shaft of the turbocharger and the common load are drivinglyinterconnected.
 8. The compound cycle engine as defined in claim 1,wherein the common load includes an output shaft having a different axisthan that of the same shaft of the turbocharger, the compressor and thepressure turbine each including at least one radial impeller.
 9. Thecompound cycle engine as defined in claim 1, wherein the common loadincludes an output shaft connected to the rotor of each unit, thevelocity turbine being drivingly engaged to the output shaft through atransmission.
 10. The compound cycle engine as defined in claim 1,further comprising common rail fuel injectors for each unit, and a heavyfuel source in communication with the fuel injectors
 11. A compoundcycle engine comprising: at least one rotary engine having a rotorsealingly and rotationally received within a respective housing havingan inlet port and an exhaust port, the rotor of each rotary engine beingdrivingly engaged to a common load; a velocity turbine in proximity ofeach rotary engine and having a rotor drivingly engaged to the commonload; a respective exhaust pipe providing fluid communication betweeneach exhaust port and the velocity turbine upstream of the rotorthereof; a turbocharger including a compressor and a pressure turbinedrivingly engaged to a same shaft; an inlet duct providing fluidcommunication between an outlet of the compressor and the inlet port ofeach rotary engine; and a turbine pipe providing fluid communicationbetween an outlet of the velocity turbine and an inlet of the pressureturbine.
 12. The compound cycle engine as defined in claim 11, whereinthe compound cycle engine includes at least two rotary engines, therespective exhaust pipe of each rotary engine being in fluidcommunication with a respective velocity turbine inlet, the velocityturbine inlets being circumferentially spaced apart.
 13. The compoundcycle engine as defined in claim 11, wherein the same shaft of theturbocharger rotates independently of the common load.
 14. The compoundcycle engine as defined in claim 11, wherein the same shaft of theturbocharger and the common load are drivingly interconnected.
 15. Thecompound cycle engine as defined in claim 11, wherein the rotor of thevelocity turbine is an axial rotor.
 16. The compound cycle engine asdefined in claim 11, wherein each rotary engine is a Wankel engine. 17.The compound cycle engine as defined in claim 11, further comprisingcommon rail fuel injectors for each rotary engine, and a heavy fuelsource in communication with the fuel injectors.
 18. A method ofcompounding at least one rotary engine, the method comprising: drivinglyengaging a pressure turbine and a compressor in a turbocharger; defininga fluid communication between an outlet of the compressor and an inletport of each rotary engine; defining a fluid communication between anexhaust port of each rotary engine and an inlet of a velocity turbine,including directing the fluid communication onto blades of a rotor ofthe velocity turbine; defining a fluid communication between an outletof the velocity turbine and an inlet of the pressure turbine of theturbocharger; and drivingly engaging each rotary engine and the velocityturbine to a common load.
 19. The method as defined in claim 18, furthercomprising providing fluid communication between a source of heavy fueland each rotary engine.
 20. The method as defined in claim 18, whereineach rotary engine has a volumetric compression ratio within a rangedefined from 6:1 to 8:1.